Toro 04018, 04206, 04022, 04202, greensmaster flex 18 Operator's Manual

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Page 1

Form No. 3356-378 Rev A

Greensmaster® Flex 18 or Flex 21 Walk-Behind Mower

Model No. 04018 (Traction Unit) —Serial No. 270000001 and Up

Model No. 04206 (Cutting Unit) —Serial No. 270000001 and Up

Model No. 04022 (Traction Unit) —Serial No. 260000001 and Up

Model No. 04202 (Cutting Unit) —Serial No. 260000001 and Up

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Warning

Model No.

CALIFORNIA

Pr oposition 65 W ar ning

T he engine exhaust fr om this pr oduct contains chemicals kno wn to the State of Calif or nia to cause cancer , bir th defects, or other r epr oducti v e har m.

T his spark ignition system complies with Canadian ICES-002

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 and Figure 2 identify the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Serial No.

Figure 2

1. Location of the model and serial numbers-Cutting Unit

Cutting unit:

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 3 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 1

1. Location of the model and serial numbers-Traction unit

T raction unit:

Figure 3

1. Safety alert symbol.

T his man ual uses tw o other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

T oro Mo w er Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Sound Pressure for a Flex 18 . . . . . . . . . . . . . . . . 7

Sound P o w er for a Flex 18 . . . . . . . . . . . . . . . . . . . . 7

Vibration for a Flex 18 . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound Pressure for a Flex 21 . . . . . . . . . . . . . . . . 7

Sound P o w er for a Flex 21 . . . . . . . . . . . . . . . . . . . . 7

Vibration for a Flex 21 . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Installing the Handle . . . . . . . . . . . . . . . . . . . . . . . 10

2 Installing the Kic kstand for Flex

18 Mo w ers Only . . . . . . . . . . . . . . . . 11

3 Adjusting the Handle . . . . . . . . . . . . . . . . . . . . . . 12

4 Installing the T ranspor t

W heels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Chec king Fluid Lev els . . . . . . . . . . . . . . . . . . . . . 13

6 Installing the Grass Bask et . . . . . . . . . . . . . . . 13

7 R eading the Man uals and Viewing

the Video . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chec king the Engine Oil Lev el . . . . . . . . . . . 18

Filling the Fuel T ank . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Chec king the Interloc k Switc h

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Star ting and Stopping the

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

T ranspor t Operation . . . . . . . . . . . . . . . . . . . . . . . . . 20

Pre paring to Mo w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Mo wing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Daily Maintenance Chec klist . . . . . . . . . . . . . . 23

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 24

R e placing the Spark Plug . . . . . . . . . . . . . . . . . . . . 25

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cleaning the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 26

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 26

Ser vicing the Interloc k Switc h . . . . . . . . . . . 26

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 27

Chec king the T ransmission Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Changing the T ransmission

Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adjusting the Ser vice/P arking

Brak e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adjusting the Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Controls System Maintenance . . . . . . . . . . . . . . . . . . . . 31

Adjusting the T raction

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Adjusting the R eel Control . . . . . . . . . . . . . . . . . 31

Cutting Unit Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Se parating the Cutting Unit from

the T raction Unit . . . . . . . . . . . . . . . 32

Adjusting the R ear R oller . . . . . . . . . . . . . . . . . . . 32

Adjusting the Bedknife to the

R eel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Adjusting the Height of Cut . . . . . . . . . . . . . . . 34

Adjusting the Cut-Off Bar . . . . . . . . . . . . . . . . . . 35

Setting the Mac hine to Matc h T urf

Conditions . . . . . . . . . . . . . . . . . . . . . . . . 36

Ser vicing the Bedbar . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Bac klapping the R eel . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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Safety

T his mac hine meets or ex ceeds CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999 speciﬁcations in effect at the time of production when the Operator Presence Kit, P ar t No . 105-5333 is installed.

• T horoughly inspect the area where the equipment is to be used and remo v e all objects whic h ma y be thro wn b y the mac hine .

• W ar ning-Fuel is highly ﬂammable . T ak e the follo wing precautions:

– Store fuel in containers speciﬁcally designed

for this pur pose .

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means CA UTION , W ARNING , or D ANGER-“personal safety instr uction." F ailure to comply with the instr uction ma y result in personal injur y or death.

Safe Operating Practices

T he follo wing instr uctions are from the CEN standard EN 836:1997, ISO standard 5395:1990, and ANSI B71.4-1999.

Training

• R ead the Operator’ s Man ual and other training material carefully . Be familiar with the controls , safety signs , and the proper use of the equipment.

• Nev er allo w c hildren or people unfamiliar with these instr uctions to use or ser vice the mo w er . Local regulations ma y restrict the ag e of the operator .

– R efuel outdoors only and do not smok e

while refuelling .

– Add fuel before star ting the engine . Nev er

remo v e the cap of the fuel tank or add fuel while the engine is r unning or when the engine is hot.

– If fuel is spilled, do not attempt to star t the

engine but mo v e the mac hine a w a y from the area of spillag e and a v oid creating any source of ignition until fuel v apors ha v e dissipated.

– R e place all fuel tanks and container caps

securely .

• R e place faulty silencers .

• Ev aluate the ter rain to deter mine what

accessories and attac hments are needed to properly and safely perfor m the job . Only use accessories and attac hments appro v ed b y the man ufacturer .

• Chec k that operator’ s presence controls , safety switc hes and shields are attac hed and functioning properly . Do not operate unless they are functioning properly .

• Nev er mo w while people , especially c hildren, or pets are nearb y .

• K ee p in mind that the operator or user is responsible for accidents or hazards occur ring to other people or their proper ty .

• T he o wner/user can prev ent and is responsible for accidents or injuries occur ring to himself or herself , other people , or proper ty .

Preparation

• W hile mo wing, alw a ys w ear substantial footw ear , long trousers , hard hat, safety glasses , and ear protection. Long hair , loose clothing, or jew elr y ma y g et tangled in mo ving par ts . Do not operate the equipment when barefoot or w earing open sandals .

Operation

• Do not operate the engine in a conﬁned space where dang erous carbon mono xide fumes can collect.

• Mo w only in da ylight or in g ood ar tiﬁcial light.

• Before attempting to star t the engine ,

diseng ag e all blade attac hment clutc hes , shift into neutral, and eng ag e the parking brak e .

• Do not use on slopes of more than 15°.

• R emember there is no suc h thing as a safe

slope . T ra v el on g rass slopes requires par ticular care . T o guard ag ainst o v er tur ning:

– do not stop or star t suddenly when g oing

up or do wnhill;

– eng ag e clutc h slo wly , alw a ys k ee p mac hine

in g ear , especially when tra v elling do wnhill;

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– mac hine speeds should be k e pt lo w on

slopes and during tight tur ns;

– sta y aler t for humps and hollo ws and other

hidden hazards;

– nev er mo w across the face of the slope ,

unless the mo w er is designed for this pur pose .

• Sta y aler t for holes in the ter rain and other hidden hazards .

• W atc h out for trafﬁc when crossing or near roadw a ys .

• Stop the blades rotating before crossing surfaces other than g rass .

• W hen using any attac hments , nev er direct disc harg e of material to w ard b ystanders nor allo w any one near the mac hine while in operation.

• Nev er operate the mac hine with damag ed guards , shields , or without safety protecti v e devices in place . Be sure all interloc ks are attac hed, adjusted properly , and functioning properly .

• Do not c hang e the engine g o v er nor settings or o v erspeed the engine . Operating the engine at ex cessi v e speed ma y increase the hazard of personal injur y .

• Before lea ving the operator’ s position:

– stop on lev el g round; – diseng ag e the po w er tak e-off and lo w er the

attac hments;

– c hang e into neutral and set the parking

brak e;

– stop the engine .

• Diseng ag e dri v e to attac hments when transpor ting or not in use .

• Stop the engine and diseng ag e dri v e to attac hment

– before refuelling; – before remo ving the g rass catc her/catc hers; – before making height adjustment unless

adjustment can be made from the operator’ s

position. – before clearing bloc kag es; – before c hec king, cleaning or w orking on

the mo w er; – after striking a foreign object or if an

abnor mal vibration occurs . Inspect the

mo w er for damag e and mak e re pairs before restar ting and operating the equipment.

• R educe the throttle setting before stopping engine and, if the engine is pro vided with a fuel shut-off v alv e , tur n the v alv e off at the conclusion of mo wing .

• K ee p hands and feet a w a y from the cutting unit.

• Slo w do wn and use caution when making tur ns and crossing roads and sidew alks . Stop reels if not mo wing .

• Do not operate the mo w er under the inﬂuence of alcohol or dr ugs

• Use care when loading or unloading the mac hine into a trailer or tr uc k

• Use care when approac hing blind cor ners , shr ubs , trees , or other objects that ma y obscure vision.

Maintenance and Storage

• K ee p all n uts , bolts and screws tight to be sure the equipment is in safe w orking condition.

• Nev er store the equipment with fuel in the tank inside a building where fumes ma y reac h an open ﬂame or spark.

• Allo w the engine to cool before storing in any enclosure .

• T o reduce the ﬁre hazard, k ee p the engine , silencer , batter y compar tment and fuel storag e area free of g rass , lea v es , or ex cessi v e g rease .

• Chec k the g rass catc her frequently for w ear or deterioration.

• K ee p all par ts in g ood w orking condition and all hardw are and h y draulic ﬁttings tightened. R e place all w or n or damag ed par ts and decals .

• If the fuel tank has to be drained, do this outdoors .

• Be careful during adjustment of the mac hine to prev ent entrapment of the ﬁng ers betw een mo ving blades and ﬁx ed par ts of the mac hine .

• Diseng ag e dri v es , diseng ag e the cutting unit, set parking brak e , stop engine and disconnect spark plug wire . W ait for all mo v ement to stop before adjusting, cleaning or re pairing .

• Clean g rass and debris from cutting unit, dri v es , m ufﬂers , and engine to help prev ent ﬁres . Clean up oil or fuel spillag e .

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• Carefully release pressure from components with stored energ y .

• Disconnect batter y and remo v e spark plug wire before making any re pairs . Disconnect the neg ati v e ter minal ﬁrst and the positi v e last. R econnect positi v e ﬁrst and neg ati v e last.

• Use care when c hec king the reel. W ear glo v es and use caution when ser vicing them.

• K ee p hands and feet a w a y from mo ving par ts . If possible , do not mak e adjustments with the engine r unning .

Toro Mower Safety

T he follo wing list contains safety infor mation speciﬁc to T oro products or other safety infor mation that y ou m ust kno w that is not included in the CEN , ISO , or ANSI standard.

T his product is capable of amputating hands and feet and thro wing objects . Alw a ys follo w all safety instr uctions to a v oid serious injur y or death.

Use of this product for pur poses other than its intended use could pro v e dang erous to user and b ystanders .

• Kno w ho w to stop the engine quic kly .

• Do not operate the mac hine while w earing

tennis shoes or sneak ers .

• W earing safety shoes and long pants is advisable and required b y some local ordinances and insurance regulations .

• Handle g asoline carefully . Wipe up any spills .

• Chec k the safety interloc k switc hes daily

for proper operation. If a switc h should fail, re place the switc h before operating the mac hine . After ev er y tw o years , re place all interloc k switc hes in the safety system, reg ardless if they are w orking properly or not.

• Alw a ys stand behind the handle when star ting and operating the mac hine .

• T o star t and stop the engine:

– Open fuel shut-off v alv e . – V erify that the traction and reel dri v e

control lev ers on handle are in Neutral position.

– Mo v e on/off switc h to ON position, set

c hok e to full c hok e position (cold star t) and throttle to half throttle .

– Pull star ter cord to star t engine .

– Mo v e throttle to Slo w and on/off switc h to

Off position to stop engine .

• T o transpor t mo w er from one area to another :

– Install transpor t wheels .

– Diseng ag e reel dri v e .

– Star t engine .

– Press do wn on handle to raise front of

mo w er and eng ag e traction dri v e .

• Before beginning mo wing operation:

– Diseng ag e traction dri v e .

– Stop engine .

– R emo v e transpor t wheels .

– Star t engine

– Eng ag e reel dri v e .

• Using the mac hine demands attention. T o prev ent loss of control:

– Do not dri v e close to sand traps , ditc hes ,

creeks , or other hazards .

– R educe speed when making shar p tur ns .

A v oid sudden stops and star ts .

– W hen near or crossing roads , alw a ys yield

the right-of-w a y .

– Apply the ser vice brak es when g oing

do wnhill to k ee p forw ard speed slo w and to maintain control of the mac hine .

• T he g rass bask et m ust be in place during operation of the reels or thatc hers for maxim um safety . Shut the engine off before emptying the bask ets .

• Do not touc h the engine , m ufﬂer , or exhaust pipe while the engine is r unning or soon after it has stopped because these areas could be hot enough to cause bur ns .

• Sta y clear of the rotating screen at the side of the engine to prev ent direct contact with y our body or clothing .

• W hen a person or pet appears unexpectedly in or near the mo wing area, stop mo wing . Careless operation, combined with ter rain angles , ricoc hets , or improperly positioned guards can lead to thro wn object injuries . Do not resume mo wing until the area is cleared.

Maintenance and Storage

• Chec k all fuel lines for tightness and w ear on a regular basis . Tighten or re pair them as needed.

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• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p hands , feet, clothing, and any par ts of the body a w a y from the cutting unit, attac hments , and any mo ving par ts , especially the screen at the side of the engine . K ee p ev er y one a w a y .

• T o ensure safety and accuracy , ha v e an A uthorized T oro Distributor c hec k the maxim um engine speed with a tac hometer . Maxim um g o v er ned engine speed should be 3600 RPM.

• If major re pairs are ev er needed or if assistance is desired, contact an A uthorized T oro Distributor .

• Use only T oro-appro v ed attac hments and re placement par ts . T he w ar ranty ma y be v oided if used with unappro v ed attac hments .

Sound Pressure for a Flex 18

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 85 dB A, based on measurements of identical mac hines per EN 11094 and EN 836.

Vibration for a Flex 21

T his unit does not ex ceed a hand/ar m vibration lev el of 2.50 m/s identical mac hines per EN 1033.

, based on measurements of

Sound Power for a Flex 18

T his unit has a guaranteed sound po w er lev el of 96 dB A, based on measurements of identical mac hines per EN 11094.

Vibration for a Flex 18

T his unit does not ex ceed a hand/ar m vibration lev el of 2.50 m/s identical mac hines per EN 1033.

, based on measurements of

Sound Pressure for a Flex 21

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 85 dB A, based on measurements of identical mac hines per EN 11094 and EN 836.

Sound Power for a Flex 21

T his unit has a guaranteed sound po w er lev el of 98 dB A, based on measurements of identical mac hines per EN 11094.

Page 8

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

105-5309

1. Hot surface/burn hazard—keep a safe distance from the hot surface.

93-7348

1. Warning—read the Operator’s Manual .

2. Fire hazard—no re, open ames, or smoking; when adding fuel to the tank, leave space between the fuel and the top of the tank.

3. Thrown object hazard—keep bystanders a safe distance from the machine.

4. Cutting hazard of hand or foot—stay away from moving parts

93-9356

1. Entanglement hazard—stay away from moving parts.

1. Fast

2. Continuous variable setting

93-6085

3. Slow

93-9886

1. Use unleaded gasoline.

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1. Parking brake

2. Disengage

104-2618

3. Engage

1. Traction drive 4. Forward

2. Reel drive 5. Lever engaged

3. Neutral 6. Lever disengaged

104-2617

93-8064

1. Warning—read the instructions before servicing or performing maintenance.

2. Cutting hazard of hand or foot—stop the engine and wait for moving parts to stop.

1. Read the Operator’s Manual .

105-2411

1. Transmission oil

104-2621

Page 10

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

3 4 5 6

Handle

Kickstand assembly Spring Small spacer Large spacer 1 Large bolt (M8–1.25 x 100) Small bolt (M8–1.25 x 030) Locknut (M8 x 1.25) Washer (M8)

No parts required

Transport wheels (Optional Transport Wheel Kit, Model 04123)

No parts required

Grass basket

Operator’s Manual Engine Operator’s Manual Parts Catalog Operator Video Certicate of compliance

Description

Qty.

1 1 1

1 1 2 2

–

1 1 1 1 1

Install the handle.

Install the kickstand for Flex 18 Mowers Only.

Adjust the handle.

Install the transport wheels.

Check the engine oil and transmission uid levels

Install the grass basket.

Read the manuals and watch the video before operating the machine.

Use

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Step

Installing the Handle

Parts needed for this step:

Handle

Procedure

1. R emo v e the ﬂang e loc k n ut from the bolt and pi v ot pin on eac h side of the mo w er ( Figure 4 ).

Figure 4

1. Flange lock nut

2. Pivot pin

2. Inser t the handle ends through the slots in the handle suppor t ar ms ( Figure 5 ).

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Figure 5

1. Left handle end

2. Support arm

3. Pivot pin

4. Locknut

3. Squeeze the handle ends inw ard and install them on the ste p of the pi v ot pin ( Figure 5 ).

4. Secure the handle to the bolt and pi v ot pin with the ﬂang e loc k n ut ( Figure 5 ).

5. Locate cable tie loosely securing throttle cable to wire har ness . P osition cable tie appro ximately one inc h behind transmission and tighten cable tie .

the kic kstand to the frame with the bolt and w asher , the small spacer , and loc kn ut (M8–1.25) ( Figure 6 ). Ensure the bolt is installed from the inside of the frame as sho wn in Figure 6 .

3. Install a w asher (M8) onto the larg e bolt (M8–1.25 x 100).

4. Install the spacer into the spring and install the larg e bolt (M8–1.25 x 100) into the spacer .

Important: W hen installing the spring , place one end of the spring under the r ear frame ( Figur e 6 ).

5. Install the left side of the kic kstand to the frame with the bolt and w asher , the larg e spacer and spring, and loc kn ut (M8–1.25) ( Figure 6 ). Ensure the bolt is installed from the inside of the frame as sho wn in Figure 6 .

Step

Installing the Kickstand for Flex 18 Mowers Only

Parts needed for this step:

Kickstand assembly

Spring

Small spacer 1 Large spacer 1

Large bolt (M8–1.25 x 100) 1

Small bolt (M8–1.25 x 030) 2

Locknut (M8 x 1.25) 2

Washer (M8)

Procedure

1. P osition the kic kstand betw een the tabs on the rear of the frame .

2. Install a w asher (M8) onto the small bolt (M8–1.25 x 030). Install the right side of

Figure 6

1. Left handle end

2. Locknut (M8–1.25)

3. Small spacer

4. Washer (M8) 8. Ssmall bolt (M8–1.25 x

5. Large bolt (M8–1.25 x 100)

6. Spring

7. Large spacer

030)

6. Place a n ut r unner o v er the end of the spring pointing to w ards the rear and mo v e the end of the spring o v er and under the kic kstand spacer ( Figure 7 ).

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Step

Installing the Transport Wheels

Figure 7

1. Spring

2. Spring end under the frame 4. Move the spring end under

3. Nut runner

the kickstand spacer.

Step

Adjusting the Handle

No Parts Required

Procedure

1. R emo v e hair pin cotters from ring pins on eac h side of mo w er ( Figure 8 ).

Parts needed for this step:

Transport wheels (Optional Transport Wheel

Kit, Model 04123)

Procedure

1. Push kic k stand do wn with foot and pull up on handle suppor t until kic k stand has rotated forw ard, o v er center ( Figure 9 ).

Figure 8

1. Ring pins

2. W hile suppor ting handle , remo v e ring pins from eac h side and raise or lo w er handle to desired operating position ( Figure 8 ).

3. R einstall ring pins and hair pin cotters .

Figure 9

1. Kick stand

2. Press wheel loc king clip to w ard the center of wheel and slide wheel onto hex shaft ( Figure 10 ).

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Figure 10

1. Locking clip

3. R otate wheel bac k and for th until it slides completely onto axle and loc king clip is secured in g roo v e on axle shaft.

Step

Installing the Grass Basket

Parts needed for this step:

Grass basket

Procedure

Grasp bask et b y top lip and slide bask et frame into the recei v ers ( Figure 11 ).

4. R e peat procedure on opposite side of mac hine .

5. Inﬂate the tires to 12-15 psi.

6. Carefully lift up on handle suppor t to release kic k stand.

Step

Checking Fluid Levels

No Parts Required

Procedure

1. Chec k the engine oil lev el, refer to Chec king the Engine Oil Lev el in Engine Maintenance , pag e 24 .

2. Chec k the transmission ﬂuid lev el, refer to Chec king the T ransmission Fluid Lev el in Dri v e System Maintenance , pag e 27 .

Figure 11

1. Grass basket 2. Basket receivers

Page 14

Step

Reading the Manuals and Viewing the Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Operator Video

Certicate of compliance

Procedure

1. R ead the man uals .

2. View the Operator video .

3. Store the documentation in a safe place .

Page 15

Product Overview

Figure 12

1. Handle

2. Control panel 6. Grass basket

3. Engine

4. Transport wheels

Controls

5. Cutting unit

7. Fuel tank

operates throttle linkag e to carburetor . Engine speed can be v aried from 2400 RPM to 3600 RPM.

Traction and Reel Drive Engagement Lever

T he traction and reel dri v e eng ag ement lev er ( Figure 13 ) is located on front right side of control panel. T raction lev er has tw o positions: Neutral and F orw ard. Pushing lev er forw ard eng ag es traction dri v e .

T he reel dri v e lev er has tw o positions: Eng ag e and Diseng ag e . Mo v e top of lev er to the left to eng ag e reel or bac k to neutral to diseng ag e reel.

Service/Parking Brake

T he ser vice/parking brak e ( Figure 13 ) is located on left front side of control panel. Pulling the lev er bac k o v er center will set the parking brak e . Brak e m ust be released before traction dri v e is eng ag ed.

Operator Presence Control

T he optional operator presence control m ust be eng ag ed before eng aging the traction lev er or the engine will stop .

Choke Lever

Figure 13

1. Throttle control 3. Service/parking brake

2. Traction & reel drive engagement lever

Throttle Control

T he throttle control ( Figure 13 ) is located on rear right side of control panel. Lev er connects to and

T he c hok e lev er ( Figure 14 ) is located on left front of engine . Lev er has tw o positions: R un and Chok e . Mo v e the c hok e lev er to the half-open position when star ting a cold engine . After engine star ts mo v e lev er to R un position.

Figure 14

1. Choke lever 2. Fuel shut-off valve

Page 16

Fuel Shut-Off Valve

T he fuel shut-off v alv e ( Figure 14 ) is located on left front of engine . V alv e has tw o positions: Closed and Open. Mo v e lev er to closed position when storing or transpor ting mac hine . Open v alv e before star ting engine .

Recoil Starter

Pull recoil star ter handle ( Figure 15 ) to star t engine .

Figure 16

1. Kick stand

Figure 15

1. Recoil starter

2. On/off switch

3. Hour meter

On/Off Switch

T he on/off switc h ( Figure 15 ) is located on rear of engine . Mo v e switc h to On position to star t engine and Off to stop engine .

Hour Meter

T he hour meter ( Figure 15 ) located on rear of engine , indicates the total hours of mac hine operation.

Kickstand

T he kic kstand ( Figure 16 ) is mounted to rear of mac hine and is used to raise rear of mac hine for installation or remo v al of transpor t wheels .

Page 17

Specications

Width 35-1/2 inches

Height 41–1/4 inches

Length with

basket

Weight with full

uids and basket

Dry weight with

basket Engine

Fuel capacity

Ground speed Mowing speed:

Width of cut

Height of cut 1/16 to 19/64

Clip frequency 11 blade

Flex 21 Flex 18

(90.1 cm)

(104.8 cm) 61–1/2 inches

(156.2 cm) 267lb (121 kg) 261lb (118 kg)

256lb (116 kg) 250lb (113 kg)

Kawasaki, 4-cycle, 3.7 (2.7 kw) air cooled OHV engine, 3600 RPM, 7.57 cu inch (124 cc) displacement, cast iron cylinder sleeve; electronic ignition with integral lighting coil; maximum noise suppression mufer; 85 dB(A) at operator’s ear

2.64 qt. (2.5 l); regular grade unleaded gasoline

1.3 to 3.3 MPH (2.1 to 5.3 km/h)Transport speed: 4.9 MPH (7.9 km/h) maximum

21 inches (53.3 cm)

inches (1.5 to 7.5 mm) with Micro-Cut bedknife

(standard): .14 in.

32 inches (81.3 cm)

41–1/2 inches (105.4 cm)

61 inches (155 cm)

2.64 qt. (2.5 l); regular grade unleaded gasoline

Mowing speed:

1.3 to 3.3 MPH (2.1 to 5.3 km/h)Transport speed: 4.9 MPH (7.9 km/h) maximum

18 inches (45.7 cm)

1/16 to 19/64 inches (1.5 to 7.5 mm) with Micro-Cut bedknife

11 blade (standard): .14 inch

g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or

Page 18

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Think Safety First

Please carefully read all of the safety instr uctions and decals in the safety section. Kno wing this infor mation could help y ou or b ystanders a v oid injur y .

Checking the Engine Oil Level

Chec k the engine oil lev el before eac h use or ev er y 8 operating hours , refer to Chec king the Engine Oil Lev el in Engine Maintenance , pag e 24 .

Filling the Fuel Tank

Important: Nev er use methanol, gasoline

containing methanol, gasohol containing mor e than 10% ethanol, gasoline additi v es, pr emium gasoline, or white gas because the fuel system could be dama ged. Do not mix oil with gasoline.

Gasoline is har mful or f atal if s w allo w ed. Long-ter m exposur e to v apor s can cause serious injur y and illness.

• A v oid pr olonged br eathing of v apor s.

• K eep f ace a w ay fr om nozzle and gas tank or conditioner opening .

• K eep gas a w ay fr om ey es and skin.

Figure 17

1. Fuel tank cap 2. Fuel gauge

Page 19

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of gasoline.

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

g asoline , ﬁll fuel tank no higher than to bottom of ﬁlter screen. Do not o v erﬁll.

2. Install fuel tank cap and wipe up any spilled g asoline .

Checking the Interlock Switch Operation

If safety inter lock s witches ar e disconnected or dama ged the machine could operate unexpectedl y causing per sonal injur y .

• Do not tamper with the inter lock s witches.

• Check the operation of the inter lock s witches dail y and r eplace an y dama ged s witches bef or e operating the machine.

• R eplace s witches ev er y tw o y ear s r egardless of whether they ar e operating pr oper l y or not.

1. Push kic k stand do wn with foot and pull up on handle suppor t until kic k stand has rotated forw ard, o v er center ( Figure 18 ).

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

1. Clean around fuel tank cap and remo v e cap from tank ( Figure 17 ). Using unleaded

Figure 18

1. Kick stand

2. Place traction lev er into Eng ag e position and engine controls in star ting position.

3. Attempt to star t engine . Engine should not star t. If engine star ts , the interloc k switc h needs ser vice . Cor rect problem before operating . R efer to Ser vicing Interloc k Switc h.

4. Carefully lift up on handle to release kic k stand.

Page 20

Starting and Stopping the Engine

Note: F or illustrations and descriptions of

the controls referenced in this section, refer to Controls , pag e 15 .

Starting the Engine Note: Mak e sure spark plug wire is installed on

spark plug .

1. Mak e sure traction and reel dri v e lev ers are in Diseng ag ed position.

Note: Engine will not star t if traction lev er is in the eng ag ed position.

2. Open the fuel shut-off v alv e on the engine .

3. Mo v e the on/off switc h to the On position.

4. Mo v e the throttle control to the F ast position.

5. Mo v e the c hok e lev er to the half-open position when star ting a cold engine . T he c hok e ma y not be required when star ting a w ar m engine .

2. T o release kic kstand, pull up on handle and lo w er rear of mo w er onto transpor t wheels .

3. Ensure traction and reel dri v e controls are in Diseng ag e position and star t engine .

4. Set throttle control to Slo w , tip front of mac hine up g radually eng ag e traction dri v e and slo wly increase engine speed.

5. Adjust throttle to operate mo w er at desired g round speed and transpor t mo w er to desired destination.

Preparing to Mow

1. R etur n traction control lev er to Diseng ag e , throttle to Slo w and stop engine .

2. Push kic k stand do wn with foot and pull up on handle suppor t until kic k stand has rotated forw ard, o v er center .

3. R emo v e transpor t wheels .

4. R elease kic kstand.

6. Pull the recoil star ter handle out until positi v e eng ag ement results , then pull it vig orously to star t the engine . Open the c hok e as engine w ar ms up .

Important: Do not pull r ecoil r ope to its limit or let go of star ter handle when r ope is pulled out because r ope may br eak or r ecoil assembl y may be dama ged.

Stopping the Engine

1. Mo v e the traction and reel dri v e controls to the Diseng ag ed position, the throttle control to Slo w , and the on/off switc h to Off .

2. Pull the molded spark plug wire off of the spark plug to prev ent the possibility of accidental star ting before storing mac hine .

3. Close the fuel shut-off v alv e before storing or transpor ting mo w er in a v ehicle .

Transport Operation

Note: Do not r un the mo w er engine while

transpor ting it in a transpor t trailer because damag e can occur to the mo w er .

1. Push kic k stand do wn with foot and pull up on handle suppor t until kic k stand has rotated forw ard, o v er center .

Mowing Operation

Proper use of the mac hine pro vides the smoothest turf cutting a v ailable .

Important: Grass clippings act as a lubricant when mo wing . Ex cessi v e operation of the cutting unit with the a bsence of g rass clippings can dama ge the cutting unit.

Prior to Mowing

Be sure the mo w er is carefully adjusted and is set ev enly on both sides of the reel. Improper mo w er adjustment is magniﬁed in the appearance of the clipped turf . R emo v e all foreign objects from turf prior to mo wing . Mak e sure ev er y one , especially c hildren and pets , are clear of the w ork area.

Method of Mowing

T he g reens should be mo w ed in a straight bac k and for th direction across the g reen. A v oid circular mo wing or tur ning the mo w er on g reens areas since scufﬁng ma y occur . T ur ning the mo w er should be done off the g reen b y raising the cutting reel (pushing the handle do wn) and tur ning on the traction dr um. Mo wing should be done at a nor mal w alking pace . F ast speeds sa v es v er y little time and will result in an inferior mo wing job .

Page 21

T o assist in maintaining a straight line across the g reen and to k ee p the mac hine an equal distance from the edg e of the previous cut, use the alignment stripes on the bask et ( Figure 19 ).

Figure 19

1. Alignment stripes

Control Operation

T o operate the controls while mo wing:

1. Star t the engine , set the throttle at reduced speed, push do wn on handle to raise cutting unit, mo v e traction lev er to Eng ag ed position and transpor t mo w er onto collar of g reen ( Figure 20 ).

2. Mo v e traction lev er to Diseng ag ed position and Eng ag e reel dri v e lev er ( Figure 20 ).

Figure 20

1. Traction drive -neutral 3. Traction drive-engaged

2. Traction drive neutral & reel drive off

(transport)

4. Traction drive & reel drive engaged

3. Mo v e traction lev er to Eng ag ed position, increase throttle speed until the mo w er is tra v eling at the desired g round speed, dri v e the mo w er out onto the g reen area, lo w er the front of the mo w er do wn and commence operation ( Figure 20 ).

After Mowing

1. Dri v e off g reen, mo v e reel dri v e and traction control lev ers to Diseng ag e and stop the engine .

2. Empty the g rass catc her of clippings , install g rass catc her and commence transpor t operation.

Page 22

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 25

operating hours

Before each use or daily

Every 25 hours

Every 50 hours

Every 100 hours

Every 200 hours

Every 1,500 hours

Before storage

Every 2 years

Maintenance Procedure

• Change the engine oil.

• Clean the fuel lter.

• Change the transmission uid.

• Check the engine oil level.

• Clean the air cleaner (more often in dirty or dusty conditions).

• Change the engine oil.

• Clean the fuel lter.

• Check the transmission uid level.

• Clean or replace the paper air lter element (more often in dirty or dusty conditions).

• Check the spark plug.

• Decarbon the engine.

• Replace the interlock switch.

• Change the transmission uid.

• Paint chipped surfaces.

• Change the transmission uid.

Important: R efer to y our engine operator’ s man ual f or additional maintenance pr ocedur es.

Page 23

Daily Maintenance Checklist

Important: Duplicate this pa ge f or r outine use.

Maintenance Check Item

Check the safety interlock operation.

Check the parking brake operation.

Check that pivot joints operate freely.

Check the fuel level.

Check the engine oil level.

Check the air lter.

Clean the engine cooling ns.

Check for unusual engine noises.

Check for unusual operating noises.

Check the reel-to-bedknife adjustment.

Check the height-of-cut adjustment.

Touch up damaged paint.

For the week of:

Mon. Tues.

Wed. Thurs.

Fri.

Sat. Sun.

Notation for Areas of Concern Inspection performed by:

Item Date

Information

Page 24

Engine Maintenance

Engine Oil

Chec k the engine oil lev el eac h time the mo w er is used or after ev er y 8 operating hours . Chang e the oil after the ﬁrst 8 operating hours and ev er y 50 hours thereafter . More frequent oil c hang es are required in dusty or dir ty conditions . T he crankcase m ust be ﬁlled with appro ximately 20 ﬂuid ounces of proper viscosity oil before staring . T he engine uses any high-quality oil ha ving the American P etroleum Institute - APl

- “ser vice classiﬁcation" SF , SG , SH or SJ . Oil viscosity - w eight - m ust be selected according to ambient temperature . Figure 21 illustrates the temperature/viscosity recommendations .

Figure 22

1. Oil level gauge 2. Drain plug

2. R emo v e oil lev el g aug e b y rotating it countercloc kwise .

Figure 21

Note: Using m ulti-g rade oils (5W -20, 10W -30,

and 10W -40) will increase oil consumption. Chec k the oil lev el more frequently when using them.

Checking the Engine Oil Level

1. P osition mo w er so the engine is lev el and clean around oil lev el g aug e ( Figure 22 ).

3. Wipe oil lev el g aug e clean and inser t it into ﬁller por t. Do not screw into por t. T hen remo v e and c hec k lev el of oil. If lev el is lo w , add only enough oil to raise lev el to bottom of ﬁller opening . R ec hec k lev el of oil. Do not o v erﬁll.

4. R einstall oil lev el g aug e and wipe up any spilled oil.

Changing the Engine Oil

1. Star t and r un engine for a few min utes to w ar m the engine oil.

2. Place a drain pan at rear of mac hine under drain plug ( Figure 22 ). R emo v e drain plug .

3. Push do wn on handle to tip mo w er and engine bac kw ard, allo wing all oil to r un into drain pan.

4. Install drain plug and reﬁll crankcase with the speciﬁed oil; refer to Chec king the Oil Lev el.

Servicing the Air Cleaner

Nor mally , clean air cleaner foam element after ev er y 25 operating hours . More frequent cleaning is required when mo w er is operated in dusty or dir ty conditions .

1. Mak e sure wire is off spark plug .

Page 25

2. R emo v e wing n uts securing air cleaner co v er to air cleaner and remo v e co v er . Clean co v er thoroughly ( Figure 23 ).

Figure 23

1. Air cleaner cover

3. If foam element is dir ty , remo v e it from paper element ( Figure 24 ). Clean thoroughly .

A. W ash foam element in a solution of liquid

soap and w ar m w ater . Squeeze to remo v e dir t, but do not twist because the foam ma y tear .

B . Dr y b y wrapping in a clean rag . Squeeze

rag and foam element to dr y , but do not twist because the foam ma y tear .

C . Saturate element with clean engine oil.

Squeeze element to remo v e ex cess oil and to distribute oil thoroughly . An oil damp element is desirable .

Figure 24

1. Foam element 2. Paper element

4. W hen ser vicing foam element, c hec k condition of paper element. Clean or re place ev er y 100 hours or as required.

5. Install foam element, paper element, and air cleaner co v er .

Important: Do not operate the engine without the air cleaner element because extr eme engine w ear and dama ge will lik el y r esult.

Replacing the Spark Plug

Use an NGK BPR 5ES spark plug or equi v alent. Cor rect air g ap is 0.028-0.032 inc h R emo v e plug after ev er y 100 operating hours and c hec k its condition.

1. Pull molded wire off spark plug ( Figure 25 ).

Page 26

Figure 25

1. Spark plug wire

2. Clean around spark plug and remo v e plug from cylinder head.

Important: R eplace a crack ed, f ouled, or dir ty spar k plug . Do not sand blast, scrape, or clean electr odes because engine dama ged could r esult fr om g rit entering the cylinder .

3. Set air g ap at 0.028-0.032 inc h ( Figure 26 ). Install cor rectly g apped spark plug and tighten ﬁr mly to 17 ft.-lb .

Figure 27

1. Shut-off valve 2. Bowl

2. Clean bo wl and ﬁlter in clean g asoline and install.

Electrical System Maintenance

Servicing the Interlock Switch

Use the follo wing procedure if the switc h needs adjustment or re placement.

1. Mak e sure the engine is off and traction lev er is Diseng ag ed.

2. Eng ag e traction lev er until it contacts neutral stop ( Figure 28 ).

Figure 26

Fuel System Maintenance

Cleaning the Fuel Filter

Initially , clean fuel ﬁlter after the ﬁrst 25 hours of operation; thereafter clean after ev er y 50 hours operation.

1. Close fuel shut off v alv e and unscrew bo wl from ﬁlter body ( Figure 27 ).

Figure 28

1. Traction lever 3. Interlock switch

2. Neutral stop

4. .032" Gap

Page 27

3. Loosen interloc k switc h mounting fasteners ( Figure 28 ).

4. Place a .032" thic k shim betw een the traction lev er and the interloc k switc h ( Figure 28 ).

5. Tighten interloc k switc h mounting fasteners . R ec hec k g ap . T he traction lev er m ust not contact the switc h.

6. Eng ag e traction lev er and v erify that the switc h loses contin uity . R e place if required.

Important: R eplace inter lock s witch ev er y 2 y ear s.

Drive System

Figure 29

1. Check/ll plug 2. Drain plug

Maintenance

Checking the Transmission Fluid Level

T he transmission is ﬁlled at the factor y with appro ximately 94 ﬂuid ounces of Mobil Dexron lll automatic transmission ﬂuid. Chec k ﬂuid lev el before the engine is ﬁrst star ted and ev er y 50 hours thereafter .

Note: T he seals used in the transmission are inter nally lubricated with g rease . During initial operation of mo w er , slight w ee ping of g rease from these seals will occur . Wipe off ex cess g rease .

Important: Use onl y Mobil Dexr on lll or equi v alent transmission ﬂuids. Other ﬂuids could cause system dama ge.

1. Place the mo w er on its dr ums on a lev el surface .

2. R emo v e the c hec k/ﬁll plug from the right-hand side of the transmission ( Figure 29 ).

3. Install the plug .

Changing the Transmission Fluid

Chang e the transmission ﬂuid after the ﬁrst 25 hours of operation and ev er y 2 years or 1500 hours , whic h ev er occurs ﬁrst thereafter .

Important: Use onl y Mobil Dexr on lll or equi v alent transmission ﬂuids. Other ﬂuids could cause system dama ge.

1. Place a drain pan at the rear of the mac hine .

2. R emo v e the drain plug from the rear of the transmission ( Figure 30 ).

T he oil lev el should come to the bottom of the ﬁll hole . If it does not, add enough of the proper oil type until the lev el reac hes the bottom of the ﬁll hole .

Figure 30

1. Check/ll plug 2. Drain plug

3. Push do wn on the handle and tip the mac hine bac k. R emo v e the c hec k/ﬁll plug from the right-hand side of the transmission ( Figure 30 ).

Page 28

4. W hen the ﬂuid is drained, install the drain plug .

Reel Drive Belt (Reel)

5. Place the mo w er on its dr ums on a lev el surface .

6. Fill the transmission with appro ximately 94 ﬂuid ounces of the proper type of transmission ﬂuid until the lev el reac hes the bottom of the c hec k/ﬁll hole; refer to Chec king the T ransmission Fluid.

7. Install the c hec k/ﬁll plug .

Brake Maintenance

Adjusting the Service/Parking Brake

If ser vice/park brak e slips when operated, an adjustment is required.

1. Mo v e ser vice/parking brak e lev er to Off position.

2. T o increase cable tension, loosen front cable jam n ut and tighten bac k cable jam n ut ( Figure 31 ) until a force of 6-9 lb . is required to eng ag e brak e . F orce to be measured at lev er knob . Do not o v er adjust, or brak e band ma y drag .

1. R emo v e the belt co v er mounting fasteners and belt co v er to expose belt ( Figure 32 ).

Figure 32

1. Belt cover

2. Chec k tension b y de pressing belt ( Figure 33 ) at mid span of pulleys with 4 ± 1 lb . of force . Belt should deﬂect 1/4 inc h (6 mm). If the deﬂection is incor rect, proceed to next ste p .

Figure 31

1. Traction cable 2. Service/parking brake cable

Belt Maintenance

Adjusting the Belts

Mak e sure belts are properly tensioned to assure proper operation of the mac hine and unnecessar y w ear . Chec k belts frequently .

Figure 33

1. Reel drive belt 3. Driven pulley

2. Drive pulley

3. T o adjust belt tension:

A. Loosen the bearing housing mounting n uts

( Figure 34 ).

Page 29

Figure 34

1. Reel drive belt 2. Bearing housing mounting nuts

B . Using a 3/8 inc h dri v e tor que wrenc h,

rotate the bearing housing with 35-40 in.-lb . of tor que to set belt tension ( Figure 35 )

Figure 36

1. Belt cover

2. Chec k tension b y de pressing belt ( Figure 37 ) at mid span of pulleys with 4 ± 1 lb . of force . Belt should deﬂect 1/4 inc h (6 mm). If the deﬂection is incor rect, proceed to next ste p .

Figure 35

1. Bearing housing 2. 3/8" Torque wrench here

C . W hile holding the tor que wrenc h setting,

tighten the bearing housing mounting n uts ( Figure 34 ). Do not o v er -tension belt.

D . Install belt co v er .

Reel Drive Belt (Transmission coupler)

1. R emo v e the belt co v er mounting fasteners and belt co v er to expose belt ( Figure 36 ).

Figure 37

1. Reel drive belt

3. T o adjust belt tension:

A. Loosen the bearing housing mounting n uts

( Figure 38 ).

Page 30

Figure 38

1. Reel drive belt 2. Bearing housing mounting nuts

B . Using a 3/8 inc h dri v e tor que wrenc h,

rotate the bearing housing with 35-40 in.-lb . of tor que to set belt tension ( Figure 39 ).

Figure 39

1. Bearing housing 2. 3/8" Torque wrench here

Figure 40

1. Traction drive belt cover

2. Chec k tension b y de pressing belt ( Figure 41 ) at mid span of pulleys with 4 ± 1 lb of force . Belt should deﬂect 1/4 inc h (6 mm). If the deﬂection is incor rect, proceed to next ste p .

C . W hile holding the tor que wrenc h setting,

tighten the bearing housing mounting n uts ( Figure 38 ). Do not o v er -tension belt.

D . Install belt co v er .

Traction Drive Belt

1. R emo v e belt co v er mounting fasteners and belt co v er to expose belt ( Figure 40 ).

Figure 41

1. Traction drive belt

3. T o adjust belt tension:

A. On bac k side of side plate , loosen the bolt

securing the idler brac k et to the side plate ( Figure 42 ).

Page 31

Figure 42

1. Tang washer 2. Idler bracket bolt

B . Using a 3/8 inc h dri v e tor que wrenc h,

rotate the idler brac k et with 35-40 in.-lb . of tor que to set the belt tension ( Figure 43 ). W hile holding the tor que wrenc h setting, tighten the idler brac k et mounting bolt (T he tang w asher is installed to prev ent the belt from slipping .). Do not o v er -tension the belt.

Controls System Maintenance

Adjusting the Traction Control

If traction control does not eng ag e or it slips during operation, an adjustment is required.

1. Mo v e traction control to Diseng ag ed position.

2. T o increase cable tension, loosen front cable jam n ut and tighten bac k cable jam n ut ( Figure 44 ) until a force of 12-16 lb . is required to eng ag e traction control.

Measure the force at the control knob .

Figure 43

1. Traction drive belt 3. 3/8 inch Torque wrench here

2. Idler bracket

C . Install the belt co v er .

Figure 44

1. Traction cable 2. Service/parking brake cable

3. Tighten front cable jam n ut.

4. Chec k control operation.

Adjusting the Reel Control

If reel control does not eng ag e or it slips during operation, an adjustment is required.

1. Mak e sure traction control is properly adjusted; refer to Adjusting the T raction Control.

2. T o increase cable tension, loosen front cable jam n ut and tighten bac k cable jam n ut ( Figure 45 ) (located on top of g ear bo x) until the reel cable force adds 7 to 10 lbs . of additional handle force measured at the control knob .

Note: If traction control handle force is 12 lbs ., the combined traction and reel force should be 19 to 22 lbs .

Page 32

Figure 45

1. Reel control cable

3. Tighten front cable jam n ut.

4. Chec k control operation.

Cutting Unit

Figure 47

1. Cutting unit pivot arms

2. Traction unit frame tube

3. Bolts

5. R otate pi v ot ar ms forw ard ( Figure 47 ) and rest traction unit on restrained kic kstand.

Maintenance

Separating the Cutting Unit from the Traction Unit

1. Place the mo w er on its dr ums on a lev el surface .

2. Lo w er kic k stand. Inser t a 1/4" dia. pin or equi v alent into frame hole abo v e kic k stand mounting bolt ( Figure 46 ).

6. Pull cutting unit forw ard about 2 inc h (51 mm) and then to the right to diseng ag e the transmission coupling ( Figure 48 ).

Figure 48

1. Transmission coupling

7. R ev erse procedure to install cutting unit.

Adjusting the Rear Roller

Figure 46

1. 1/4" Pin 3. Kick stand

2. Handle

3. R emo v e g rass bask et.

4. R emo v e (2) bolts securing cutting unit pi v ot ar ms to traction unit frame tube ( Figure 47 ).

1. Adjust the rear roller brac k ets to the lo w or high position de pending on desired height of cut rang e ( Figure 49 and Figure 50 ).

• P osition the spacer abo v e the side plate mounting ﬂang e (factor y setting) when height of cut settings rang e from 1/16 to 1/4" (Fig . 10).

Page 33

Figure 49

1. Spacer

2. Sideplate mounting ange

3. Roller bracket

• P osition the spacer belo w the side plate mounting ﬂang e when height of cut settings rang e from 1/8" to 1" ( Figure 50 ).

Note: T he position of the rear roller to the reel is controlled b y the mac hining tolerances of the assembled components and paralleling is not required. A limited amount of adjustment is possible b y setting the cutting unit on a surface plate and loosening the side plate mounting bolts ( Figure 51 ). Adjust and re-tighten bolts .

Figure 51

1. Sideplate mounting bolts

Figure 50

1. Sideplate mounting ange 3. Roller bracket

2. Spacer

2. T o adjust rear roller proceed as follo ws:

• Raise rear of cutting unit and place a bloc k under bedknife .

• R emo v e (2) n uts securing eac h roller brac k et and spacer to eac h side plate mounting ﬂang e .

• Lo w er roller and screws from side plate mounting ﬂang es and spacers .

• Place spacers onto screws on roller brac k ets .

• R e-secure roller brac k et and spacers to underside of side plate mounting ﬂang es with n uts previously remo v ed.

Important: W henev er the cutting unit has to be tipped to expose bedknife/r eel, pr op up r ear of cutting unit to mak e sur e n uts on back end of bedbar adjusting scr ews ar e not r esting on w or k surf ace.

Adjusting the Bedknife to the Reel

Bedknife to reel adjustment is accomplished b y loosening or tightening bedbar adjusting screws , located on top of mo w er .

1. P osition mac hine on a ﬂat, lev el w ork surface .

2. Mak e sure reel contact is remo v ed b y tur ning bedbar adjusting screws countercloc kwise ( Figure 52 ).

3. V erify that the bedknife to reel contact is cor rect. Tip mo w er to expose front and rear rollers and bedknife .

Page 34

Figure 52

1. Bedbar adjusting screw

3. Tilt mo w er on bac k to expose bedknife and reel.

4. At one end of reel, inser t a long strip of newspaper betw een reel and bedknife ( Figure 53 ). W hile slo wly rotating reel forw ard, tur n bedbar adjusting screw cloc kwise (on same end of reel) ( Figure 52 ), one clic k at a time , until paper is pinc hed lightly , when inser ted from the front, parallel to the bedknife . A slight drag will be noted as the paper is pulled.

angle to the bedknife ( Figure 53 ). It should be possible to cut paper with minim um contact betw een the bedknife and the reel blades . Should ex cessi v e reel drag be evident it will be either necessar y to bac klap or reg rind the cutting unit to ac hiev e the shar p edg es needed for precision cutting (see T oro reel shar pening man ual).

Adjusting the Height of Cut

F or heights of cut g reater than .500", the high height of cut kit m ust be installed.

1. Loosen loc kn uts securing height-of-cut ar ms to cutting unit side plates ( Figure 54 ).

Figure 53

Note: Eac h time adjusting screw is rotated

one clic k cloc kwise , the bedknife mo v es .0007 inc h closer to reel. Do not o v er tighten the adjusting screws .

5. Chec k for light contact at other end of reel using paper and adjust as required.

6. After adjustment is accomplished, c hec k to see if reel can pinc h paper when inser ted from the front and cut paper when inser ted at a right

Figure 54

1. Rear roller bracket 3. Locknut

2. Height-of-cut arm 4. Adjusting screw

2. Loosen n ut on g aug e bar ( Figure 55 ) and set adjusting screw to desired height-of-cut. Distance betw een bottom of screw head and face of bar is height-of-cut.

Page 35

Figure 55

1. Gauge bar

2. Height adjusting screw

3. Nut

3. Hook screw head on cutting edg e of bedknife and rest rear end of bar on rear roller ( Figure 56 ).

1. Loosen screws securing top bar ( Figure 57 ) to cutting unit.

Figure 57

1. Cut-off bar

2. Inser t .060 inc h feeler g aug e betw een top of reel and bar and tighten screws . Ensure bar and reel are equal distance apar t across complete reel.

Figure 56

4. R otate adjusting screw until roller contacts front of g aug e bar . Adjust both ends of roller until entire roller is parallel to the bedknife .

Important: W hen set pr oper l y , the r ear and fr ont r oller s will contact the gauge bar and the scr ew will be sn ug a gainst the bedknife. T his ensur es that the height-of-cut is identical at both ends of the bedknife.

5. Tighten n uts to secure adjustment. Do not o v er tighten n ut. Tighten enough to remo v e pla y from w asher .

Note: Use the follo wing c har t to deter mine whic h bedknife is best suited for the desired height of cut.

Note: T he bar is adjustable to compensate for c hang es in turf conditions . T he bar should be adjusted closer to reel when turf is extremely dr y . By contrast, adjust bar fur ther a w a y from reel when turf conditions are w et. T he bar should be parallel to reel to ensure optim um perfor mance and should be adjusted whenev er reel is shar pened on a reel g rinder .

Adjusting the Cut-Off Bar

Adjust cut-off bar to assure clippings are cleanly disc harg ed from the reel area:

Page 36

Setting the Machine to Match Turf Conditions

Use the follo wing table to set the mac hine to matc h turf conditions .

Flex Greensmower Cutting Unit Set-up Matrix

Bedbars: Standard and Optional

Part Number

106-2468-01 99-3794-03 110-2282-01 110-2281-03

Bedknives: Standard and Optional

Part Number

93-4262 93-4263 93-4264 Low Cut 108-4303 98-7261 98-7260 110-2300 110-2301 Low Cut

Description

Standard Flex 21 Aggressive Standard Flex 18 Aggressive

Description

Microcut Tournament

Extended Microcut Flex 21 0.062 - 0.125 inches Microcut Tournament Extended Microcut Flex 18 0.062 - 0.125 inches

Mower

Flex 21

Flex 18

Mower

Flex 21 0.062 - 0.125 inches Standard Flex 21 0.125 -0.25 inches Flex 21 0.25 inches and up

Flex 18 0.062 - 0.125 inches Standard Flex 18 0.125 -0.25 inches

Flex 18 0.25 inches and up

Aggressiveness

Less

Height of Cut Range

Comments

Standard

Comments

Less Aggressive

Rollers: Standard and Optional Part Number

107-9037 107-9038 107-9039 107-9036 106-6945 110-2304 110-2305 110-2306 110-2303

Description

Narrow Wiehle Flex 21 2.5 inches Aluminum Standard Front Wide Wiehle Flex 21 2.5 inches Aluminum Full Roller Flex 21 2.5 inches Steel Rear Roller Flex 21 2.0 inches Aluminum Standard Rear Rear Roller Flex 21 2.0 inches Steel Steel Rear Narrow Wiehle Flex 18 2.5 inches Aluminum Standard Front Wide Wiehle Flex 18 2.5 inches Aluminum Full Roller Flex 18 2.5 inches Steel Rear Roller Flex 18 2.0 inches Aluminum Standard Rear

Mower

Diameter/Material

Comments

More Penetration Least Penetration

Page 37

Use the follo wing table and Figure 58 to set the rate of clip .

Clip (Refer to Figure 58 for pulley locations.) Drive pulley number of

teeth

27 22 22 22 22 27

Driven pulley number of teeth

T he reel is shipped with one 27 tooth and one 22 tooth pulley . T o g et a .16 inc h clip , y ou m ust purc hase a 22 tooth pulley . T he clip can only be c hang ed on the reel dri v e ( Figure 58 ). Do not c hang e the dri v e ratio on the g earbo x pulleys .

11 Blade Clip 8 Blade Clip

.14 inches (standard)

.16 inches .24 inches .21 inches .29 inches

Figure 59

1. Bedbar adjusting screw

2. Spring tension nut

3. Bedbar

4. Jam nut

5. Bedbar bolt

.19 inches

Figure 58

1. Reel drive belt 3. Driven pulley

2. Drive pulley

Servicing the Bedbar

Removing the Bedbar

1. T ur n the bedbar adjuster screw , countercloc kwise , to bac k the bedknife a w a y from reel ( Figure 59 ).

2. Bac k out the spring tension n ut, until the w asher is no long er tensioned ag ainst the bedbar ( Figure 60 ).

3. On eac h side of the mac hine , loosen the jam n ut securing the bedbar bolt ( Figure 60 ).

Figure 60

1. Bedbar bolt

2. Nut

4. R emo v e eac h bedbar bolt allo wing bedbar to be pulled do wnw ard and remo v ed from mac hine . Account for 2 nylon and 2 stamped steel w ashers on eac h end of bedbar ( Figure 61 ).

Page 38

Figure 61

1. Bedbar bolt

2. Steel washer 4. Nylon washer

3. Nut

Assembling the Bedbar

1. Install bedbar , positioning mounting ears betw een w asher and bedbar adjuster .

2. Secure bedbar to eac h side plate with bedbar bolts (jam n uts on bolts) and 8 w ashers . A nylon w asher is to be positioned on eac h side of side plate boss . Place a steel w asher outside eac h of the nylon w ashers . T or que bolts to 240-320 in.-lb .

3. Tighten the jam n ut until the end pla y is remo v ed from the outside thr ust w ashers . Do not o v er tighten.

Note: It is acce ptable that the inside thr ust w ashers on the cutting unit ma y remain loose .

4. Tighten spring tension n ut until spring is collapsed, then bac k off 1/2 tur n.

5. Adjust bedbar; refer to Adjusting the Bedknife to the R eel.

Backlapping the Reel

1. R emo v e plug from the reel dri v e co v er on the left side of reel assembly ( Figure 62 )

Figure 62

1. Reel drive cover plug

2. Inser t a 18 mm soc k et onto hex ﬂang e n ut on left end of reel shaft.

3. Bac klap according to the procedure in the T oro Shar pening R eel and R otar y Mo w ers Man ual, F or m No . 80-300 PT .

Contact with the r eel or other mo ving par ts can r esult in per sonal injur y .

• Stay a w ay fr om the r eel while backlapping .

• Nev er use a shor t handled paint br ush f or backlapping . P ar t No. 29-9100 Handle assembl y complete or indi vidual par ts ar e a v aila ble fr om y our local Authoriz ed T or o Distributor .

Note: F or a better cutting edg e , r un a ﬁle across the front face of the bedknife when the lapping operation is completed. T his will remo v e any bur rs or rough edg es that ma y ha v e built up on the cutting edg e .

4. R einstall plug when bac klap operation is completed.

Page 39

Storage

1. R emo v e g rass clippings , dir t, and g rime from the exter nal par ts of the entire mac hine , especially the engine . Clean dir t and c haff from the outside of the engine’ s cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not pr essur e w ash the machine. A v oid ex cessi v e use of w ater , especiall y near the shift lev er plate, and engine.

2. F or long-ter m storag e (more than 90 da ys) add stabilizer/conditioner additi v e to fuel in the tank.

A. R un the engine to distribute conditioned

fuel through the fuel system (5 min utes).

B . Either stop engine , allo w it to cool, and

drain the fuel tank, or operate the engine until it stops .

C . R estar t the engine and r un it until it stops .

R e peat, on Chok e , until the engine will not restar t.

D . Dispose of fuel properly . R ecycle as per

local codes . Note: Do not store stabilizer/conditioned

g asoline o v er 90 da ys .

3. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed or defecti v e .

4. P aint all scratc hed or bare metal surfaces . P aint is a v ailable from y our A uthorized Ser vice Dealer .

5. Store the mac hine in a clean, dr y g arag e or storag e area. Co v er the mac hine to protect it and k ee p it clean.

Page 40

The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product") to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs rst. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.

* P r o d u c t e q u i p p e d w i t h h o u r m e t e r

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists.

If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 800-982-2740

E-mail: commercial.service@toro.com

Owner Responsibilities

As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

• Product failures which result from the use of non-Toro

replacement parts, or from installation and use of add-on, modied, or unapproved accessories

• Product failures which result from failure to perform required

maintenance and/or adjustments

• Product failures which result from operating the Product in

an abusive, negligent or reckless manner

• Parts subject to consumption through use unless found to be

defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, blades, reels, bedknives, tines, spark plugs, castor wheels, tires, lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

• Failures caused by outside inuence. Items considered to be

outside inuence include, but are not limited to, weather, storage practices, contamination, use of unapproved coolants, lubricants, additives, or chemicals, etc.

• Normal “wear and tear" items. Normal “wear and tear"

includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.

Parts

Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part.

Parts replaced under this warranty become the property of Toro. Toro will make the nal decision whether to repair any existing part or assembly or replace it. Toro may use factory remanufactured parts rather than new parts for some warranty repairs.

General Conditions

Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.

Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and tness for use are limited to the duration of this express warranty.

Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights which vary from state to state.

Note regarding engine warranty: The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement printed in your operator’s manual or contained in the engine manufacturer’s documentation for details.

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0031 Rev C